Composite thermal isolating masonry tie fastener

ABSTRACT

Cavity walls include fasteners that provide a thermal break. A cavity wall assembly includes a support structure, insulation, and an outer wythe. The insulation is mounted on the support structure. The outer wythe is spaced apart from the insulation, such that a cavity is formed between the insulation and the outer wythe. A tie is attached to the outer wythe. A fastener extends through a portion of the tie, through the insulation, and into the support structure to attach the tie to the support structure. The fastener provides a thermal break between the support structure and the tie. At least a portion of the thermal break is disposed within a width of the insulation.

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser.No. 61/900,449, filed Nov. 6, 2013, titled COMPOSITE THERMAL ISOLATINGMASONRY TIE FASTENER”, the entire disclosure of which is incorporated byreference in its entirety.

FIELD OF THE INVENTION

The present inventions relate to thermally isolated anchoring systemsfor insulated walls. In particular, the present invention relates toanchoring systems that minimize heat transfer through a fastener thatextends through an insulation material.

BACKGROUND OF THE INVENTION

Published US Patent Application Pub. No. 2011/0047919 provides abackground of anchoring systems. Portions of US Patent Application Pub.No. 2011/0047919 are incorporated below. US Patent Application No.2011/0047919 is incorporated herein by reference in its entirety.

In the past, anchoring systems have taken a variety of configurations.The construction of a steel frame of a commercial or residentialbuilding, to which masonry veneer is attached, uses steel studs withinsulation installed outboard of the steel stud framing. Steel anchorsand ties attach the outer masonry wythe to the inner steel stud framingby screwing or bolting an anchor to a steel stud. Steel is an extremelygood conductor of heat. The use of steel anchors attached to steelframing draws heat from the inside of a building through the exteriorsheathing and insulation, towards the exterior of the masonry wall. USPatent Application No. 2011/0047919 recognizes that in order to maintainhigh insulation values, a thermal break or barrier is needed between thesteel framing and the outer wythe.

SUMMARY

The present application discloses fasteners that provide a thermal breakin cavity walls. In one exemplary embodiment, a cavity wall assemblyincludes a support structure, insulation, and an outer wythe. Theinsulation is mounted on the support structure. The outer wythe isspaced apart from the insulation, such that a cavity is formed betweenthe insulation and the outer wythe. A tie is attached to the outerwythe. A fastener extends through a portion of the tie, through theinsulation, and into the support structure to attach the tie to thesupport structure. The fastener provides a thermal break between thesupport structure and the tie. For example, in one exemplary embodiment,at least a portion of the thermal break is disposed within a width ofthe insulation.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings which are incorporated in and constitute apart of the specification, embodiments of the invention are illustrated,which, together with a general description of the invention given above,and the detailed description given below, serve to provide examples ofthe principles of this invention.

FIG. 1 is a perspective view of an exemplary embodiment of a fastenerwith a thermal break;

FIG. 1A is a perspective view of another exemplary embodiment of afastener with a thermal break;

FIG. 1B is a perspective view of another exemplary embodiment of afastener with a thermal break;

FIG. 1C is a perspective view of another exemplary embodiment of afastener that provides a thermal break;

FIG. 1D is a perspective view of another exemplary embodiment of afastener that provides a thermal break;

FIG. 2 is a perspective view of an exemplary embodiment of an anchoringsystem that uses a fastener illustrated by FIG. 1, FIG. 1A, and/or FIG.1B applied to a cavity wall assembly with an inner support structure,one or more layers of exterior sheathing, and an outer wythe of brick;

FIG. 3 is a cross-sectional view of FIG. 2 taken along an xz-planeincluding the longitudinal axis of the fastener;

FIG. 4A is a top view of an exemplary embodiment of a veneer tie;

FIG. 4B is a perspective view of the veneer tie illustrated by FIG. 4A;

FIG. 5A is a top view of another exemplary embodiment of a veneer tie;

FIG. 5B is a perspective view of the veneer tie illustrated by FIG. 5A;

FIG. 6 is a perspective view of an exemplary embodiment of an anchoringsystem that uses a fastener illustrated by FIG. 1, FIG. 1A, and/or FIG.1B and/or a veneer tie illustrated by FIGS. 5A, and 5B applied to acavity wall assembly with an inner support structure, one or more layersof exterior sheathing, and an outer wythe of brick;

FIG. 7 is a cross-sectional view of FIG. 7 taken along an xz-planeincluding the longitudinal axis of the fastener;

FIG. 8A is a top view of another exemplary embodiment of a veneer tie;

FIG. 8B is a perspective view of the veneer tie illustrated by FIG. 8A;

FIG. 9 is a perspective view of an exemplary embodiment of an anchoringsystem that uses a fastener illustrated by FIG. 1, FIG. 1A, and/or FIG.1B and/or a veneer tie illustrated by FIGS. 8A and 8B applied to acavity wall assembly with an inner support structure, one or more layersof exterior sheathing, and an outer wythe of brick;

FIG. 10 is a cross-sectional view of FIG. 9 taken along an xz-planeincluding the longitudinal axis of the fastener; and

FIG. 11 is a graph that plots Temperature vs. Time of a steel stud, astandard fastener and tie, and a fastener with a thermal breakpositioned inside the insulation and a tie.

DETAILED DESCRIPTION

As described herein, when one or more components are described as beingconnected, joined, affixed, coupled, attached, or otherwiseinterconnected, such interconnection may be direct as between thecomponents or may be indirect such as through the use of one or moreintermediary components. Also as described herein, reference to a“member,” “component,” or “portion” shall not be limited to a singlestructural member, component, or element but can include an assembly ofcomponents, members or elements.

In the embodiments described herein, the inner wythe is provided withinsulation. In exemplary embodiments disclosed herein, the insulation isapplied to the outer surface thereof of sheathing and/or drywall.Anchoring systems for cavity wall assemblies are used to secure veneerfacings to a building and overcome seismic and other forces, i.e. windshear, etc.

Exemplary embodiments of wall anchoring systems 110 are disclosed in thepresent application. Each of the wall anchoring systems include afastener 10. The fastener 10 can take a wide variety of different forms.In the examples illustrated by FIGS. 1, 1A, and 1B, the fastener 10includes a thermal break 12 or the fastener can be made from a materialhaving a low thermal conductivity, such as plastic (See FIGS. 1C an 1D)that provide a thermal break. The thermal break 12 can take a widevariety of different forms. Referring to FIG. 3, in one exemplaryembodiment, the thermal break 12 is positioned on the fastener 10, suchthat the thermal break is positioned within the width W of theinsulation 126. In one exemplary embodiment, the thermal break isprovided across the entire width W of the insulation 126. For example,the fasteners 10 illustrated by FIGS. 1C and 1D that are made fromplastic provide a thermal break across the entire width of theinsulation. In another embodiment, the entire portion of the fastener 10that is within the width W of the insulation 126 provides a thermalbreak, while one or more other portions of the fastener are conductive.

In the exemplary embodiments illustrated by FIGS. 1, 1A, 1B, 1C, and 1D,the fastener 10 includes a head 14, a threaded portion 16, and anoptional unthreaded shank 18. In another exemplary embodiment, theentire length of the fastener 10 is threaded. In the examplesillustrated by FIGS. 1, 1A, and 1B, the fastener 10 includes a thermalbreak. One or more thermal breaks 12 can be positioned anywhere alongthe threaded portion 16 and/or the unthreaded shank 18. The thermalbreaks can take a wide variety of different forms. In one exemplaryembodiment, the thermal break 12 is between 0.010 and 0.500 inches wide(i.e. along the axis of the fastener).

In the examples illustrated by FIGS. 1C and 1D, the entire head 14and/or the entire optional shank 18 are made from a non-thermallyconductive material, such as plastic, such that the entire unthreadedshank 18 provides a thermal break. In one exemplary embodiment, theentire head 14, the entire optional shank 18, and the entire threadedportion are made from a non-thermally conductive material, such asplastic, such that the entire fastener provides a thermal break.

The head 14 can take a wide variety of different forms. For example, thehead 14 can be a head that is configured to be driven by a conventionaldriver, such that a special tool is not required. For example, theillustrated head 14 has a hexagonal configuration for driving with awrench or socket. The head could also be configured to accept a bit,such as a blade bit, a Phillips head bit, a hex bit, a torqx bit, etc.In another exemplary embodiment, the head 14 is configured forattachment to a veneer tie (See, for example, FIG. 6 of US Patent No.2011/0047919). Referring to FIG. 1C, in one exemplary embodiment thehead 14 includes an integral large washer 15. The integral large washer15 may be included on any of the fasteners 10 illustrated by FIGS. 1,1A, 1B, and 1D. Incorporating the large washer 15 directly on thefastener makes the fastener easier to install, since there are fewersteps and pieces. In one exemplary embodiment, the integral large washer15 can include any of the features of the tie retaining devices 440, 540or the composite tie 840 described below. In one exemplary embodiment,the diameters of the washers disclosed by this application are at leasttwice as large as the largest diameter of the hexagonal (or other shape)of the driven portion of the head. For example, the washers disclosed bythis application can be between 1″ and 3″ in diameter. The large washer15 (or the washers of the retaining devices 440, 540 or the compositetie 840) distribute load when a pressure differential is present on thefoam (i.e. wind load).

The threaded portion 16 can take a wide variety of different forms. Inthe examples illustrated by FIGS. 1, 1A, and 1B, the threaded portion 16has a cutting end 20 that is configured to cut through a metal stud 117(See FIG. 3) and threads 22 that are configured to secure the fastener10 to the metal stud. In another exemplary embodiment, the threadedportion 16 is configured to cut into wood, for example a wood stud orpanel, or masonry, for example cinder block or poured concrete. However,the threaded portion can take any form that secures the fastener 10 tothe metal stud. For example, in one exemplary embodiment, the cuttingend 20 can be omitted.

The unthreaded shank 18 can take a wide variety of different forms. Inthe example illustrated by FIG. 1, the unthreaded shank 18 includes alarge diameter portion 160 and a small diameter portion 158. In theexample illustrated by FIG. 1A, the unthreaded shank 18 includes only alarge diameter portion 160. In the example illustrated by FIG. 1B, theunthreaded portion 18 includes only a small diameter portion 158, suchthat a portion that is approximately the same diameter as the major ormaximum diameter of the threaded portion 16. However, when included, theunthreaded shank 18 can take any form.

FIGS. 2 and 3 illustrate an exemplary embodiment of an anchoring system110. This anchoring system 110 includes a fastener 10, and a veneer tie140. A cavity wall assembly 112 is shown as having an inner wythe 114constructed from one or more panels 116 or layers, which may besheetrock, drywall, particle board, oriented strand board, fiberglassmats on the front and back of a fiberglass reinforced gypsum core,and/or any other wall construction panel or facing material, mounted ona support structure 117, such as a metal stud or column, a wood supportstructure, such as a wood stud or panel, and/or a masonry supportstructure, such as a cinder block or poured concrete. The illustratedsupport structure 117 is a metal stud, but inner wythes constructed ofmasonry materials and/or wood framing (not shown) are also applicable.The cavity wall assembly also includes an outer wythe or facing wall 118of brick 120 construction. Between the inner wythe 114 and the outerwythe 118, a cavity 122 is formed. The cavity 122 has attached to theexterior surface 124 of the inner wythe 114 an optional air or air-vaporbarrier 125 and insulation 126. The barrier 125 may be an air barrier,an air and vapor barrier, and/or an air barrier and vapor retarder withsome vapor permeance, such as about 1 perm. The air or air-vapor barrier125 and/or the panel 116 form an exterior layer of the inner wythe 114,which exterior layer has the insulation 126 disposed thereon. Theinsulation 126 can take a wide variety of different forms. Rigid foaminsulation boards are illustrated, but the insulation 126 can take anyform.

Successive bed joints 130 and 132 may be substantially planar andhorizontally disposed, in accord with current building standards. Forexample, the bed joints may be 0.375-inch (approx.) in height. Selectiveones of bed joints 130 and 132, which are formed between courses ofbricks 120, are constructed to receive a veneer anchor 140. The veneeranchor can take a wide variety of different forms. In the exampleillustrated by FIG. 2, any veneer anchor 140 capable of being mounted tothe inner wythe 114 and insulation 126 with a conventional fastener orcan be mounted with one of the fasteners 10 having a thermal break 12illustrated by FIGS. 1, 1A, and 1B. In the exemplary embodimentillustrated by FIG. 2, the veneer anchor 140 is a simple “L” shapedmetal bracket or strap. Being threadedly mounted in the inner wythe, thefastener 10 and tie or anchor 140 is supported. Referring to FIGS. 2 and3, at intervals along a horizontal surface 124, fasteners 10 and ties oranchors 140 are driven into place in holes 148 in the insulation. Theties 140 are positioned on surface 124 so that the longitudinal axis ofthe fastener 10 is normal to an xy-plane and taps into column 117.

For purposes of discussion, the cavity surface 124 of the inner wythe114 contains a horizontal line or x-axis 134 and intersecting verticalline or y-axis 136. A horizontal line or z-axis 138, normal to thexy-plane, passes through the coordinate origin formed by theintersecting x- and y-axes. FIG. 3 is a sectional view taken throughthis xz plane. As can be seen in FIG. 3, the location of the thermalbreak 12 is inside the width W of the insulation 126 in an exemplaryembodiment. This positioning of the thermal break 12 inside theinsulation significantly reduces heat transfer from one side of theinsulation to the other side of the insulation. For example, in thewinter the temperature inside a building and thus the temperature of thesupport structure 117 may be a room temperature between 65 and 75degrees F., while the temperature of the outer wythe 118 and the cavity122 may be below freezing. If a conventional metal fastener that doesnot have a thermal break within the width of the insulation 126, heatwill conduct from the support structure 117, such as a metal stud,directly through the fastener, to the head of the fastener, and be lostin the cavity 122 that is much colder than the support structure 117. Byproviding a fastener 10 with a thermal break 12 within the width of theinsulation 126, heat will conduct from the support structure 117, suchas a metal stud and into the fastener, but the thermal breaksubstantially prevents heat from passing to the head of the fastener,and from being lost in the colder cavity 122.

In an exemplary embodiment, one or more thermal breaks 12 can bepositioned anywhere in the insulation 126. In the example illustrated byFIG. 3, thermal break(s) can be positioned as indicated by referencenumbers 12, 12′ and/or 12″. Any number of thermal breaks can beprovided. In the illustrated embodiment, the fastener 10 includes ametallic portion 30 that extends into the insulation 126 from theoutside 32 and a metallic portion 34 that extends into the insulation126 from the inside, with one or more thermal breaks 12, 12′, and/or 12″disposed completely in the insulation.

The thermal break 12 can take a wide variety of different forms. Forexample, two or more parts of the fastener 10 can be connected by amaterial having a low thermal conductivity to form the thermal break 12.For example, the two or more parts can be connected together by an epoxyor other adhesive having a low thermal conductivity, mechanicallyconnected together, for example by one or more threaded connectorshaving a low thermal conductivity, and the like. Any manner forproviding a thermal break can be implemented. In another exemplaryembodiment, the entire fastener 10 is made from a material having a lowthermal conductivity, rather than providing a thermal break.

FIGS. 4A and 4B illustrate an exemplary embodiment of a tie retainingdevice 440 that can be used with a conventional fastener, such as athreaded fastener, or any of the fasteners 10 disclosed by the presentapplication and a conventional tie. The illustrated tie retaining devicecomprises a disk 402 and a tie retainer 404. In an exemplary embodiment,the disk 402 is made from a material that is substantiallynon-conductive, such as plastic. The disk 402 includes a central hole406 that is sized to accept threaded portion 16 and shank 18 of thefastener and such that the head 14 engages the disk 402. The tieretainer 404 extends away from the disk 402 to provide an opening 408for an end (See the strap tie 140 illustrated by FIG. 2) or legs 610 ofa tie (See FIG. 6).

If a conventional metal fastener is used directly with the metal tiestrap 140 illustrated by FIGS. 2 and 3, heat will conduct from thesupport structure 117, such as a metal stud, directly through thefastener and the metal strap 140, and be lost in the cavity 122 and theouter wythe 118 that are much colder than the support structure 117. Byusing the retaining device 440 with a conventional fastener or afastener 10 and a metal tie 140, a thermal break is provided between themetal tie 140 and the conventional fastener or a fastener 10. Theplastic material of the disk 402 provides the thermal break.

FIGS. 5A and 5B illustrate another exemplary embodiment of a tieretaining device 540 that can be used with a conventional fastener, suchas a threaded fastener, or any of the fasteners 10 disclosed by thepresent application and a conventional tie. The illustrated tieretaining device comprises a disk 502 and a tie retainer 504. In anexemplary embodiment, the disk 502 and the tie retainer 504 are madefrom a material that is substantially non-conductive, such as plastic.The disk 502 includes a central hole 506 that is sized to accept thethreaded portion 16 and shank 18 of the fastener 10, such that the head14 engages the disk 402. The tie retainer 504 extends away from the disk502 to provide an opening 508 for an end of a strap tie 140 (See FIG. 2)or legs (See FIG. 6) of a tie 140.

If a conventional metal fastener is used directly with the metal tiestrap 140 illustrated by FIGS. 2 and 3, heat will conduct from thesupport structure 117, such as a metal stud, directly through thefastener and the metal strap, and be lost in the cavity 122 and theouter wythe 118 that are much colder than the support structure 117. Byusing the retaining device 540 with a conventional fastener or afastener 10 and a metal tie 140, a thermal break is provided between themetal tie 140 and the conventional fastener or a fastener 10. Theplastic material of the disk 502 and the tie retainer 504 provide thethermal break.

FIGS. 6 and 7 illustrate a wall anchoring system 610 that uses fasteners10 shown in FIGS. 1, 1A and/or 1B and the tie retaining device 540illustrated by FIG. 5. A cavity wall assembly 112 is shown as having aninner wythe 114 constructed from one or more panels 116 or layers, whichmay be sheetrock, drywall, particle board, oriented strand board,fiberglass mats on the front and back of a fiberglass reinforced gypsumcore, and/or any other wall construction panel or facing material,mounted on a support structure 117, such as metal studs-117. Innerwythes constructed of masonry materials and/or wood framing (not shown)are also applicable. The cavity wall assembly also includes an outerwythe or facing wall 118 of brick 120 construction. Between the innerwythe 114 and the outer wythe 118, a cavity 122 is formed. The cavity122 has attached to the exterior surface 124 of the inner wythe 114 anoptional air or air-vapor barrier 125 and insulation 126. The air orair-vapor barrier 125 and/or the panel 116 form an exterior layer of theinner wythe 114, which exterior layer has the insulation 126 disposedthereon.

Successive bed joints 130 and 132 may be substantially planar andhorizontally disposed, in accord with current building standards. Forexample, the bed joints may be 0.375-inch (approx.) in height. Selectiveones of bed joints 130 and 132, which are formed between courses ofbricks 120, are constructed to receive a veneer anchor or tie 140. Theveneer anchor or tie can take a wide variety of different forms. In theexample illustrated by FIG. 6, any veneer anchor 140 capable of beingmounted to the inner wythe 114 and insulation 126 with a conventionalfastener or can be mounted with one of the fasteners 10 having a thermalbreak 12 illustrated by FIGS. 1, 1A, and 1B can be used. In theexemplary embodiment illustrated by FIG. 6, the veneer tie 140 is aformed from wire with legs 610 that fit in the opening 508. The veneertie 140 is shown in FIG. 1 on a course of bricks 120 in preparation forembedment in the mortar of a bed joint 130.

Referring to FIGS. 6 and 7, at intervals along a horizontal surface 124,fasteners 10 are driven into place in holes 148 in the insulation. Theties 140 are positioned on surface 124 so that the longitudinal axis ofwall anchor 140 is normal to an xy-plane and the fastener 10 taps intocolumn 117. For purposes of discussion, the cavity surface 124 of theinner wythe 114 contains a horizontal line or x-axis 134 andintersecting vertical line or y-axis 136. A horizontal line or z-axis138, normal to the xy-plane, passes through the coordinate origin formedby the intersecting x- and y-axes. FIG. 7 is a sectional view takenthrough this xz plane. As can be seen in FIG. 7, the location of thethermal break 12 is inside the width W of the insulation 126 in anexemplary embodiment. This positioning of the thermal break 12 insidethe insulation significantly reduces heat transfer from one side of theinsulation to the other side of the insulation. For example, in thewinter the temperature inside a building and thus the temperature of thesupport structure 117, such as a metal stud, may be a room temperaturebetween 65 and 75 degrees F., while the temperature of the outer wythe118 and the cavity 122 may be below freezing. If a conventional metalfastener that does not have a thermal break within the width of theinsulation 126, heat will conduct from the support structure 117, suchas a metal stud, directly through the fastener, to the head of thefastener, and be lost in the cavity 122 that is much colder than thesupport structure 117. By providing a fastener 10 with a thermal break12 within the width of the insulation 126, heat will conduct from thesupport structure 117, such as a metal stud and into the fastener, butthe thermal break substantially prevents heat from passing to the headof the fastener, and from being lost in the colder cavity 122.

In an exemplary embodiment, one or more thermal breaks 12 can bepositioned anywhere in the insulation 126. In the example illustrated byFIG. 7, thermal break(s) can be positioned as indicated by referencenumbers 12, 12′ and/or 12″. Any number of thermal breaks can beprovided. In the illustrated embodiment, the fastener 10 includes ametallic portion 30 that extends into the insulation 126 from theoutside 32 and a metallic portion 34 that extends into the insulation126 from the inside, with one or more thermal breaks 12, 12′, and/or 12″disposed completely in the insulation.

The thermal break 12 can take a wide variety of different forms. Forexample, two or more parts of the fastener 10 can be connected by amaterial having a low thermal conductivity to form the thermal break 12.For example, the two or more parts can be connected together by an epoxyor other adhesive having a low thermal conductivity, mechanicallyconnected together, for example by one or more threaded connectorshaving a low thermal conductivity, and the like. Any manner forproviding a thermal break can be implemented. In another exemplaryembodiment, the entire fastener 10 is made from a material having a lowthermal conductivity, rather than providing a thermal break.

FIGS. 8A and 8B illustrate an exemplary embodiment of a composite tie840 that can be used with a conventional fastener, such as a threadedfastener, or any of the fasteners 10 disclosed by the presentapplication. The illustrated composite tie 840 comprises a disk 802 anda wire loop 804. In an exemplary embodiment, the disk 802 is made from amaterial that is substantially non-conductive, such as plastic. The disk802 includes a central hole 806 that is sized to accept the threadedportion 16 and shank 18 of the fastener 10, such that the head 14engages the disk 802. The tie retainer wire loop 804 extends away fromthe disk 802. The disk 802 provides a thermal break between the fastener10 or a conventional fastener and the tie retainer wire loop 804.

FIGS. 9 and 10 illustrate a wall anchoring system 910 that usesfasteners 10 shown in FIGS. 1, 1A and/or 1B and the composite tie 840illustrated by FIGS. 8A and 8B. A cavity wall assembly 112 is shown ashaving an inner wythe 114 constructed from one or more panels 116 orlayers, which may be sheetrock, drywall, particle board, oriented strandboard, fiberglass mats on the front and back of a fiberglass reinforcedgypsum core, and/or any other wall construction panel or facingmaterial, mounted on a support structure 117, such as metal studs orcolumns, wood studs or panels, or a masonry wall. Metal studs areillustrated, but inner wythes constructed of masonry materials and/orwood framing (not shown) are also applicable. The cavity wall assemblyalso includes an outer wythe or facing wall 118 of brick 120construction. Between the inner wythe 114 and the outer wythe 118, acavity 122 is formed. The cavity 122 has attached to the exteriorsurface 124 of the inner wythe 114 an optional air or air-vapor barrier125 and insulation 126. The air or air-vapor barrier 125 and/or thepanel 116 form an exterior layer of the inner wythe 114, which exteriorlayer has the insulation 126 disposed thereon.

Successive bed joints 130 and 132 may be substantially planar andhorizontally disposed, in accord with current building standards. Forexample, the bed joints may be 0.375-inch (approx.) in height. Selectiveones of bed joints 130 and 132, which are formed between courses ofbricks 120, are constructed to receive a veneer anchor 140. The veneeranchor can take a wide variety of different forms. In the exampleillustrated by FIG. 2, any veneer anchor 140 capable of being mounted tothe inner wythe 114 and insulation 126 with a conventional fastener canbe mounted with one of the fasteners 10 having a thermal break 12illustrated by FIGS. 1, 1A, and 1B. The tie retainer wire loop 804 isdisposed on a course of bricks 120 in preparation for embedment in themortar of bed joint 130.

Referring to FIGS. 9 and 10, at intervals along a horizontal surface124, fasteners 10 are driven into place in holes 148 in the insulation.The ties 140 are positioned on surface 124 so that the longitudinal axisof wall anchor 140 is normal to an xy-plane and the fastener 10 tapsinto column 117.

For purposes of discussion, the cavity surface 124 of the inner wythe114 contains a horizontal line or x-axis 134 and intersecting verticalline or y-axis 136. A horizontal line or z-axis 138, normal to thexy-plane, passes through the coordinate origin formed by theintersecting x- and y-axes. FIG. 10 is a sectional view taken throughthis xz plane. As can be seen in FIG. 10, the location of the thermalbreak 12 is inside the width W of the insulation 126 in an exemplaryembodiment. This positioning of the thermal break 12 inside theinsulation significantly reduces heat transfer from one side of theinsulation to the other side of the insulation. For example, in thewinter the temperature inside a building and thus the temperature of thesupport structure 117, such as a metal stud, may be a room temperaturebetween 65 and 75 degrees F., while the temperature of the outer wythe118 and the cavity 122 may be below freezing. If a conventional metalfastener that does not have a thermal break within the width of theinsulation 126, heat will conduct from the support structure 117, suchas a metal stud, directly through the fastener, to the head of thefastener, and be lost in the cavity 122 that is much colder than thesupport structure 117, By providing a fastener 10 with a thermal break12 within the width of the insulation 126, heat will conduct from thesupport structure 117, such as a metal stud and into the fastener, butthe thermal break substantially prevents heat from passing to the headof the fastener, and from being lost in the colder cavity 122.

In an exemplary embodiment, one or more thermal breaks 12 can bepositioned anywhere in the insulation 126. In the example illustrated byFIG. 10, thermal break(s) can be positioned as indicated by referencenumbers 12, 12′ and/or 12″. Any number of thermal breaks can beprovided. In the illustrated embodiment, the fastener 10 includes ametallic portion 30 that extends into the insulation 126 from theoutside 32 and a metallic portion 34 that extends into the insulation126 from the inside, with one or more thermal breaks 12, 12′, and/or 12″disposed completely in the insulation.

The thermal break 12 can take a wide variety of different forms. Forexample, two or more parts of the fastener 10 can be connected by amaterial having a low thermal conductivity to form the thermal break 12.For example, the two or more parts can be connected together by an epoxyor other adhesive having a low thermal conductivity, mechanicallyconnected together, for example by one or more threaded connectorshaving a low thermal conductivity, and the like. Any manner forproviding a thermal break can be implemented. In another exemplaryembodiment, the entire fastener 10 is made from a material having a lowthermal conductivity, rather than providing a thermal break.

FIG. 11 is a graph that represents results of a test that was run on afastener 10 used in the anchoring systems 110 illustrated by FIGS. 3, 7,and 10. In the test, a metal stud 117 is made from steel and is heated.The line 1102 on the graph represents the temperature of the steel stud.Two fasteners are attached to the metal stud. The first fastener is madefrom steel and does not include a thermal break. The second fastener isalso made from steel, but has a thermal break about midway through thethickness of the insulation. The line 1104 on the graph represents thetemperature of the head of the steel fastener without a thermal break.The line 1106 on the graph represents the temperature of the head of thesteel fastener with a thermal break positioned in the insulation 126. Ascan be seen in FIG. 11, the drop in temperature from the stud to thefastener head is much greater when the fastener includes a thermal breakinside the thickness of the insulation. In the example illustrated byFIG. 11, the temperature drop from the steel stud 117 to the fastenerhead 14 doubles, at least doubles, or approximately doubles when athermal break inside the insulation is included. In the exampleillustrated by FIG. 11, the temperature drop for a steel fastenerwithout a thermal break is about 20 degrees F. (About 130 degrees F.minus about 110 degrees F.) and the temperature drop for a steelfastener with a thermal break is about 40 degrees (About 130 degreesminus about 90 degrees). As such, the inclusion of a thermal break in asteel fastener inside the width of the insulation significantly reducesthe thermal conductivity of the fastener 10.

While various inventive aspects, concepts and features of the inventionsmay be described and illustrated herein as embodied in combination inthe exemplary embodiments, these various aspects, concepts and featuresmay be used in many alternative embodiments, either individually or invarious combinations and sub-combinations thereof. Unless expresslyexcluded herein all such combinations and sub-combinations are intendedto be within the scope of the present inventions. Still further, whilevarious alternative embodiments as to the various aspects, concepts andfeatures of the inventions—such as alternative materials, structures,configurations, methods, circuits, devices and components, hardware,alternatives as to form, fit and function, and so on—may be describedherein, such descriptions are not intended to be a complete orexhaustive list of available alternative embodiments, whether presentlyknown or later developed. Those skilled in the art may readily adopt oneor more of the inventive aspects, concepts or features into additionalembodiments and uses within the scope of the present inventions even ifsuch embodiments are not expressly disclosed herein. Additionally, eventhough some features, concepts or aspects of the inventions may bedescribed herein as being a preferred arrangement or method, suchdescription is not intended to suggest that such feature is required ornecessary unless expressly so stated. Still further, exemplary orrepresentative values and ranges may be included to assist inunderstanding the present disclosure, however, such values and rangesare not to be construed in a limiting sense and are intended to becritical values or ranges only if so expressly stated. Moreover, whilevarious aspects, features and concepts may be expressly identifiedherein as being inventive or forming part of an invention, suchidentification is not intended to be exclusive, but rather there may beinventive aspects, concepts and features that are fully described hereinwithout being expressly identified as such or as part of a specificinvention. Descriptions of exemplary methods or processes are notlimited to inclusion of all steps as being required in all cases, nor isthe order that the steps are presented to be construed as required ornecessary unless expressly so stated.

While the present invention has been illustrated by the description ofembodiments thereof, and while the embodiments have been described inconsiderable detail, it is not the intention of the applicant torestrict or in any way limit the scope of the invention to such detail.Additional advantages and modifications will readily appear to thoseskilled in the art. For example, the specific locations of the componentconnections and interplacements can be modified. Therefore, theinvention, in its broader aspects, is not limited to the specificdetails, the representative apparatus, and illustrative examples shownand described. Accordingly, departures can be made from such detailswithout departing from the spirit or scope of the applicant's generalinventive concept.

1. A cavity wall assembly comprising: a support structure; insulationmounted on the support structure; an outer wythe spaced apart from theinsulation, such that a cavity is formed between the insulation and theouter wythe; a tie attached to the outer wythe; a fastener that extendsthrough a portion of the tie, through the insulation, and into thesupport structure to attach the tie to the support structure; whereinthe fastener provides a thermal break between the support structure andthe tie; wherein at least a portion of the thermal break is disposedwithin a width of the insulation.
 2. The cavity wall assembly of claim 1wherein the fastener comprises first and second metal portions with thethermal break disposed between the metal portions.
 3. The cavity wallassembly of claim 1 wherein an entire portion of the fastener that isdisposed within the width of the insulation provides a thermal breakbetween the support structure and the tie.
 4. The cavity wall assemblyof claim 1 wherein the entire fastener is made from a material thatprovides a thermal break between the support structure and the tie. 5.The cavity wall assembly of claim 1 wherein the support structurecomprises metal studs.
 6. The cavity wall assembly of claim 2 whereinthe first metal portion extends into the insulation from a first side ofthe insulation.
 7. The cavity wall assembly of claim 3 wherein thesecond metal portion extends into the insulation from a second side ofthe insulation.
 8. The cavity wall assembly of claim 3 wherein the firstside of the insulation faces toward the studs.
 9. The cavity wallassembly of claim 3 wherein the first side of the insulation facestoward the outer wythe.
 10. The cavity wall assembly of claim 1 whereinpanels are mounted between the metal studs and the insulation.
 11. Thecavity wall assembly of claim 7 wherein a vapor barrier is disposed onthe panels.
 12. The cavity wall assembly of claim 1 wherein the tiecomprises a disk portion that provides a thermal break between thefastener and the outer wythe.
 13. The cavity wall assembly of claim 9wherein a diameter of said disk portion is at least twice as large as amaximum dimension of a head of the fastener.
 14. A cavity wall assemblycomprising: metal studs; panels mounted on the metal studs; insulationmounted on the panels; an outer wythe spaced apart from the insulation,such that a cavity is formed between the insulation and the outer wythe;a tie attached to the outer wythe; a fastener that extends through aportion of the tie, through the insulation, through one of the panels,and into one of the metal studs to attach the tie to the metal stud;wherein the fastener comprises first and second metal portions with thethermal break disposed between the metal portions; wherein the firstmetal portion extends into the insulation from a first side of theinsulation; wherein the second metal portion extends into the insulationfrom a second side of the insulation; wherein the thermal break isdisposed between the first and second sides of the insulation within awidth of the insulation.
 15. The cavity wall assembly of claim 11wherein a vapor barrier is disposed on the panels.
 16. The cavity wallassembly of claim 11 wherein the tie comprises a disk portion thatprovides a thermal break between the fastener and the outer wythe. 17.The cavity wall assembly of claim 13 wherein a diameter of said diskportion is at least twice as large as a maximum dimension of a head ofthe fastener.
 18. A cavity wall assembly comprising: a supportstructure; insulation mounted on the support structure; an outer wythespaced apart from the insulation, such that a cavity is formed betweenthe insulation and the outer wythe; a tie attached to the outer wythe; afastener that extends through an enlarged disk portion of the tie,through the insulation, and into one of the metal studs to attach thetie to the support structure; wherein a diameter of said enlarged diskportion is at least twice as large as a maximum dimension of a head ofthe fastener; wherein the enlarged disk portion provides a thermal breakbetween the outer wythe and the fastener.
 19. The cavity wall assemblyof claim 15 wherein the fastener comprises first and second metalportions with the thermal break disposed between the metal portions,wherein the first metal portion extends into the insulation from a firstside of the insulation, wherein the second metal portion extends intothe insulation from a second side of the insulation, and wherein thethermal break is disposed between the first and second sides of theinsulation within a width of the insulation.
 20. The cavity wallassembly of claim 15 wherein an entire portion of the fastener that isdisposed within a width of the insulation provides a thermal breakbetween the support structure and the tie.
 21. The cavity wall assemblyof claim 15 wherein the entire fastener is made from a material thatprovides a thermal break between the support structure and the tie. 22.The cavity wall assembly of claim 15 wherein the support structurecomprises metal studs.
 23. The cavity wall assembly of claim 15 whereinthe fastener and the enlarged disk portion are integrally formed.